Method of manufacturing a compound laminar material

ABSTRACT

A method of manufacturing a compound laminar material is obtained by separately treating with resins, two webs of paper, covering with an adhesive resin both surfaces of a web of synthetic resin, applying the two webs of paper to the web of synthetic resin, one on each side thereof, pressing the resulting triple web and varnishing it, thus obtaining an imitation of parchment obtained from goatskin.

1' ,v i, United States atet [72] Inventor Jose Guarro Tapis Avda. Jose Antonio 575, Barcelona, Spain [21] Appl. No. 887,865 [22] Filed Dec. 24, 1969 [45] Patented Dec. 21, 1971 [32] Priority Dec. 28, 1968 [33] Spain 362,317

[54] METHOD OF MANUFACTURING A COMPOUND LAMINAR MATERIAL 4 Claims, 10 Drawing Figs.

[52] U.S.Cl 156/191), 156/191, 156/278, 156/324 [5 I 1 Int. Cl B321 [50] Field of Search 156/190, 191, 324, 278, 280

[56] References Cited UNITED STATES PATENTS 2,273,677 2/1942 Wallach 156/280 X 2,325,584 8/1943 Barnhart 156/280 2,425,805 8/1947 Hyman 156/324 X 2,432,575 12/1947 King 156/324 2,433,965 1/1948 Upson 156/230 2,652,351 9/1953 Gerhardt 156/280 X 2,822,855 2/1958 Sproull et 31.. 156/324 X 3,408,240 10/1968 Willams 156/324 X 3,462,329 8/1969 Beyer 156/190 Primary ExaminerCarl D. Quarforth Assistant Examiner-Gary G. Solyst An0rneySughrue, Rothwell, Mion, Zinn & Macpeak Pmmmmm 3'629'031 sum 1 OF 3 FlG.i

I INVENTOR JOSE GUARRO TAPIS BY SuO\ -Q Row, M

ATTORNEYS PATENTEU BEC21 i971 SHEET 3 BF 3 FIG. 10

METHOD OF MANUFACTURING A COMPOUND LAMINAR MATERIAL BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a compound laminar material and to the process for the obtention thereof. The product obtained is specially suited for decorative applications, particularly shades, the resulting laminar material being an imitation of leather, parchment, wood, woven material or other materials, starting out basically from a material such as paper combined with other materials of a resin type.

SUMMARY OF THE INVENTION According to the process in question, the following operations are performed on a continuous paper web in a first phase: impregnation with a first resin, drying, treatment with a second resin for color control, drying and winding up; on the other hand, in a second phase, the following operations are performed on a continuous web of synthetic resin: covering of both surfaces of the synthetic resin web with a homogenous layer of adhesive resin, drying of this latter resin and winding up; in a third phase the synthetic resin web treated according to the second phase is combined with two webs of paper treated in the first phase, by way of the following operations: application of an adhesive layer to one side of one of the two paper webs, drying of the adhesive resin, application of the synthetic resin web to said side by way of a set of rollers, winding up of the resulting complex double web, application of a layer of adhesive to the remaining paper web, drying of the adhesive resin, application of the synthetic resin face of the above complex double web against said side, by way of a set of rollers and winding up of said complex triple web; in a fourth phase the complex triple web is subjected to a pressing operation; and, finally, a fifth phase is performed whereby at least one side of the complex triple web is varnished, this operation bringing to a close the obtaining of the compound laminar material.

DETAILED DESCRIPTION OF THE INVENTION The pressing operation performed in the fourth phase may be done flat, as for example, by way of a single or multiple platen press, by way of intermittent pressing operations or linearly as, for example, by way of a calendar or pairs of horizontal or vertical pressure rollers.

The varnishing is performed horizontally, preferably by means of eccentrically moving varnishing discs.

Other aims and characteristics of the invention will be mentioned in detail in the following description, with reference to the accompanying illustrative drawings. In the drawings:

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 to 4 are a schematic representation of the development of the different phases comprising the process for obtaining the compound laminar product;

FIG. 5 is a schematic representation of one way of pressing the compound laminations by way of pairs of pressure rolls;

FIG. 6 is a schematic representation of one way of pressing the compound laminations by way of calendaring;

FIG. 7 is a schematic representation of a way of pressing the compound laminations by way ofa multiple platen press;

FIG. 8 is a schematic representation of the varnishing phase of the compound laminations;

FIG. 9 is a schematic representation ofa semicontinuous installation for the practical performance of the process of the invention; and

FIG. 10 is the schematic representation of a continuous installation for the practical performance of the process covered by the invention.

DETAILED DESCRIPTION OF THE DRAWINGS In the first phase of the process (FIG. I) the operation starts from a paper web unwound from a reel 3, which paper web is impregnated on one side by a resin through the impregnation means 4, then passes immediately afterwards through a curved drying tunnel 5, after which a further impregnation process is performed on the same side with a color control resin, through second impregnating means 6 to produce a lamination 8 which passes through a second-drying tunnel 7 to be finally taken up on a reel 9.

On the other hand, in a second phase (FIG. 2), the operation starts from a synthetic resin web 2, contained on a reel 10, said web is covered on both sides by a homogenous layer of an adhesive resin drawn from two coating means 11 and 12, after which the resulting lamination 13 passes through drying means 14 and is taken up on a reel 15.

In the third phase (FIG. 3), the laminated paper web 8, prepared according to the first phase, is taken and there is applied to one of its sides a layer of adhesive material by way of the impregnating means 16 followed immediately by drying in a curved drying tunnel 17, after which said paper lamination is combined with the synthetic resin lamination 13, obtained in the second phase, by way of a set of pressure rollers 18, to form a compound double lamination 19 which is taken up on a reel 20.

Also (FIG. 4) a further paper lamination 8 is subjected to a like operation on the basis of having a layer of adhesive material applied to it in second impregnating means 21, being dried in a second curved drying tunnel 22. Then said lamination 8 is combined with the complex double lamination 19 by way of a second set of pressure rollers 23 to produce a compound triple lamination 24 which is taken up on a reel 25.

Thus said compound triple lamination 24 comprises a prepared resin lamination 13 arranged between two-prepared paper laminations 8.

A fourth phase comprises a pressing operation on the compound triple lamination 24, for which purpose three systems may be followed: (a) pressing by means of a range of roller pairs 27 (FIG. 5); (b) pressing in a coller calendar 270 (FIG. 6); and (c) pressing in a multiple platen press 26 (FIG. 7).

The fifth and final phase comprises a varnishing operation performed on the compound triple lamination 24, which operation may be performed by way of varnishing discs moving eccentrically on a table 29.

The phases shown isolatedly in FIGS. 1 to 4 and which, according to said figures, would oblige staged manufacture, may be combined together with a view to obtaining semicontinuous processes, as in FIG. 9 which combines the phases shown in FIGS. 2 and 3, or continuous processes, as in FIG. 10 which combines the phases shown in FIGS. 2, 3 and 4.

As has been mentioned above, the process herein described may be used for obtaining an extensive range of products, outstanding among which are those which could be called synthetic animal skin which provides an imitation to all intents and purposes similar to that of legitimate animal parchment obtained from goatskin.

As a result of the different evaporation capacities of the resins and solvents used in calculated proportions, together with suitable, diverse absorption capacities of the paper used, certain random stains and transparency irregularities are produced over a certain predetermined length, all of which affords such a synthetic material an appearance very similar to animal parchment obtained from goatskin.

The product obtained may have different gauges and the most suitable for its use in the manufacture of lampshades are:

Thick gauge 0.45 mm.

Thin gauge imitation with the use of embossed papers, or by creating wrinkles, in the present invention the irregular stains are obtained by the combination of the different evaporation capacities of the chemicals used, together with the zonally adjusted absorption capacity and variation of the paper used, achieved by way of suitable mechanical means.

What i claim is:

1. A process for obtaining a compound laminar material comprising: a first phase, in which the following operations are subsequently performed on a continuous web of paper: impregnation with a first resin, drying, treatment with a second color controlling resin, drying and winding up the resultant paper web; a second phase, in which the following operations are performed on a continuous web of synthetic resin: covering on both sides of the synthetic resin web with a homogenous layer of adhesive resin, then drying of the resin and winding-up the resultant synthetic resin web; a third phase in which the web of synthetic resin treated according to the second phase is combined with two webs of paper treated according to the first phase, with the following operations: application of a layer of adhesive to one side of one of the two paper webs, drying of the adhesive resin, application, by way of a set of rollers, of the synthetic resin web against said side, the winding-up of the resulting complex double web, application of a layer of adhesive to one side of the other paper web, drying of the adhesive, application, by way of a set of rollers, of the synthetic resin side of the above complex double web to said side and winding up of the complex triple web; a fourth phase in which the complex triple web is subjected to a pressing operation; and, finally a fifth phase comprising a varnishing of at least one side of the complex triple web, which finishes the process for obtaining a compound laminar material.

2. A process for obtaining a compound laminar material, according to claim 1, in which the pressing operation performed in the fourth phase is carried out horizontally with a platen press in intermittent pressing operations.

3. A process for obtaining a compound laminar material, according to claim 1, in which the pressing operation performed in the fourth phase is carried out linearly with a calendar comprising pairs of rollers.

4. A process for obtaining a compound laminar material, according to claim 1, in which the varnishing is performed horizontally with a varnishing discs fitted with eccentric motron, 

2. A process for obtaining a compound laminar material, according to claim 1, in which the pressing operation performed in the fourth phase is carried out horizontally with a platen press in intermittent pressing operations.
 3. A process for obtaining a compound laminar material, according to claim 1, in which the pressing operation performed in the fourth phase is carried out linearly with a calendar comprising pairs of rollers.
 4. A process for obtaining a compound laminar material, according to claim 1, in which the varnishing is performed horizontally with a varnishing discs fitted with eccentric motion. 